深孔镀铬系统的控制电路设计研究
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摘要
随着现代工业自动化的不断发展,电镀技术在社会各领域的应用愈来愈广泛,电镀行业激烈的竞争促使企业提高产品质量和技术水平,面对生产质量较差,生产技术水平不高的现实,如何实现电镀自动控制技术,具有十分重要的意义。
某厂向我们提出了制作深孔镀铬控制柜的要求,针对该厂对电镀产品功能的控制要求,本系统采用的是一种集散控制系统——上位机采用组态软件WINCC和下位机采用PLC协同工作的控制系统,实现了电镀生产线的自动控制。
本文以镀铬自动控制系统为研究对象,重点对控制系统的硬件部分进行了设计和分析,按照项目的控制要求,通过AutoCAD electrical 2006软件对电气原理图的重点设计,为PLC端子图、外接端子图和施工图提供了电路依据,为镀铬控制系统的施工提供了硬件保障,保证了镀铬控制系统的顺利完成。
本文对镀铬控制系统的可靠性做了充分的分析和研究,我们从元器件选型,手动、自动、手自动的三种控制方式的切换、控制系统电磁兼容性设计以及对PLC采取了一些抗干扰措施等方面进行可靠性设计,保证了控制系统的可靠运行。
针对复杂的镀铬生产线中难免会发生故障的问题,我们在控制面板上安装了故障集控器,它的设计使工作人员能够在工艺流程出现故障时,及时的发现故障并解决,保证了控制系统的可靠性和安全性。
此外,本文还对控制系统采用模糊故障树分析法。通过对控制系统造成故障的所有可能原因的分析和总结,建立了深孔镀铬控制系统故障树模型;通过故障树定性分析,确定了最小割集;采用模糊集合理论,确定了底事件发生的概率;通过故障树定量分析,计算出顶事件发生的概率以及底事件的重要度;为系统的维护与检修提供了依据。
本控制系统经过我们研究小组精心地设计、安装、调试后,投入生产使用并能够实现电镀生产线的自动控制,验证了系统的可行性。
With the continuous development of modern industrial automation, plating technology applications more widely in all areas of society, explosive competition of electroplating industry encourage enterprises to improve product quality and technical level, to confront the reality that poor production quality and low technological level, how to achieve automatic control technology of electroplating which has great significance.
A factory requires us to create the deep hole chrome plating control cabinet, in connection with control requirements of the electroplating product features, the system uses a distributed control system, which upper computer with configuration software WINCC and lower computer with PLC collaborative work, achieving automatic control of electroplating production line.
This paper is according to chrome plating automatic control system for the study, focusing on the hardware design and analysis of control system, in accordance with control requirements of the project, through the AutoCAD electrical 2006 software designing electrical schematic diagram for the PLC terminal maps, external terminal maps and construction drawings to provide the circuit basis, for the construction of chrome plating control system to provide a hardware protection, to ensure the chrome plating control system complete successfully.
In this paper, the reliability of the chrome plating control system to do a full analysis and research, from the component selection, hand, auto, hand and auto the three control modes switching, EMC design of control system and has taken a number of PLC anti-interference measures for the reliability design, to ensure reliable operation of the control system.
In connection with the problem which complex chrome plating production line will inevitably occur faults, we installed fault set of controller on the control panel, it is designed to enable staff to timely discovery and resolve faults in process, to ensure that reliability and security of the control system.
In addition, the paper used fuzzy fault tree analysis for control system. Caused by the control system of all possible causes of fault analysis and concluded, established the fault tree model of deep hole chrome plating control system; through qualitative analysis of the fault tree to determine the minimum cut sets; using fuzzy set theory to determine the probability of occurrence of the end events; through quantitative analysis of the fault tree to calculate the probability of top event and the importance of the end events; provided the basis for Maintenance and repair of the system.
The control system has been carefully to design, installation, commissioning by our research team, put into production use and can realize automatic control of electroplating production line, to verify the feasibility of the system.
某厂向我们提出了制作深孔镀铬控制柜的要求,针对该厂对电镀产品功能的控制要求,本系统采用的是一种集散控制系统——上位机采用组态软件WINCC和下位机采用PLC协同工作的控制系统,实现了电镀生产线的自动控制。
本文以镀铬自动控制系统为研究对象,重点对控制系统的硬件部分进行了设计和分析,按照项目的控制要求,通过AutoCAD electrical 2006软件对电气原理图的重点设计,为PLC端子图、外接端子图和施工图提供了电路依据,为镀铬控制系统的施工提供了硬件保障,保证了镀铬控制系统的顺利完成。
本文对镀铬控制系统的可靠性做了充分的分析和研究,我们从元器件选型,手动、自动、手自动的三种控制方式的切换、控制系统电磁兼容性设计以及对PLC采取了一些抗干扰措施等方面进行可靠性设计,保证了控制系统的可靠运行。
针对复杂的镀铬生产线中难免会发生故障的问题,我们在控制面板上安装了故障集控器,它的设计使工作人员能够在工艺流程出现故障时,及时的发现故障并解决,保证了控制系统的可靠性和安全性。
此外,本文还对控制系统采用模糊故障树分析法。通过对控制系统造成故障的所有可能原因的分析和总结,建立了深孔镀铬控制系统故障树模型;通过故障树定性分析,确定了最小割集;采用模糊集合理论,确定了底事件发生的概率;通过故障树定量分析,计算出顶事件发生的概率以及底事件的重要度;为系统的维护与检修提供了依据。
本控制系统经过我们研究小组精心地设计、安装、调试后,投入生产使用并能够实现电镀生产线的自动控制,验证了系统的可行性。
With the continuous development of modern industrial automation, plating technology applications more widely in all areas of society, explosive competition of electroplating industry encourage enterprises to improve product quality and technical level, to confront the reality that poor production quality and low technological level, how to achieve automatic control technology of electroplating which has great significance.
A factory requires us to create the deep hole chrome plating control cabinet, in connection with control requirements of the electroplating product features, the system uses a distributed control system, which upper computer with configuration software WINCC and lower computer with PLC collaborative work, achieving automatic control of electroplating production line.
This paper is according to chrome plating automatic control system for the study, focusing on the hardware design and analysis of control system, in accordance with control requirements of the project, through the AutoCAD electrical 2006 software designing electrical schematic diagram for the PLC terminal maps, external terminal maps and construction drawings to provide the circuit basis, for the construction of chrome plating control system to provide a hardware protection, to ensure the chrome plating control system complete successfully.
In this paper, the reliability of the chrome plating control system to do a full analysis and research, from the component selection, hand, auto, hand and auto the three control modes switching, EMC design of control system and has taken a number of PLC anti-interference measures for the reliability design, to ensure reliable operation of the control system.
In connection with the problem which complex chrome plating production line will inevitably occur faults, we installed fault set of controller on the control panel, it is designed to enable staff to timely discovery and resolve faults in process, to ensure that reliability and security of the control system.
In addition, the paper used fuzzy fault tree analysis for control system. Caused by the control system of all possible causes of fault analysis and concluded, established the fault tree model of deep hole chrome plating control system; through qualitative analysis of the fault tree to determine the minimum cut sets; using fuzzy set theory to determine the probability of occurrence of the end events; through quantitative analysis of the fault tree to calculate the probability of top event and the importance of the end events; provided the basis for Maintenance and repair of the system.
The control system has been carefully to design, installation, commissioning by our research team, put into production use and can realize automatic control of electroplating production line, to verify the feasibility of the system.
引文
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[33]崔刚,孟庆波,刘文召.电磁兼容EMC控制技术浅析[J].郑州铁路职业技术学院学报. 2008,12 :3-5.
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[2] Zhang bingqian. Electroplating production line status and development[J]. Electroplating & Finishing,1994,16(6):2-3.
[3]傅健.PLC在电镀生产线行车控制系统中的应用[J].电气自动化,2006,28(2):64-67.
[4] Huang Ruiguang. Plating engineering current development and trends [J].Electroplating & Finishing,1995,17(2):3.
[5]向荣.总结电镀业成长经验研究21世纪可持续性战略[J].材料保护,2000,(1):54-55.
[6] Guan Tao. The status of the electroplating industry[J].Metal world,2005,(1):8-9
[7]张立茗.我国电镀设备的发展和状况[J].电镀与精饰,2001,23(5):13-17.
[8] Zhan Bojun. Electroplating automatic production line status and development issues[J].Electroplating & Pollution control,1982,(3):38-41.
[9] Nie Chunquan. Automatic electroplating production line control system[J]. Industrial control technology,2005,(4):95-97.
[10] Yu Weixin. Electroplating process and development[J]. Space technology,1995,(2):54-56.
[11]刘新,张红健,宫迎辉.电镀生产线自动控制系统[J].制造业自动化,2006,(10):61-63.
[12]周杰.基于WINCC的深孔镀铬监控系统设计与应用研究[D].硕士学位论文.山西:中北大学,2008.4.
[13]李菲.基于PLC的油田污水处理监控系统设计与实现[D].硕士学位论文.湖北:华中科技大学,2008.6.
[14]赵晓明,李晓勇.全自动电镀生产线的研发. 2003中国电子制造技术论坛会,2003.8: 348-352.
[15]刘新,张红健,宫迎辉.电镀铬生产线自动控制系统[J].制造业自动化, 2006,28(10).2006,10: 61-63.
[16] SIEMENS Co. SIMATIC S7-300 and M7-300 Programmable Controllers Module Specifications, EWA 4NEB 710 6067-02 01,2006.
[17]黄佳伟.电镀生产线自动控制系统的设计与实现[D].硕士学位论文.江苏:江南大学,2009.8.
[18]黄晓华.壁板铣床数控系统硬件结构的研究怀开发[D].硕士学位论文.大连:大连理工大学,2000.3.
[19]高士杰.基于控制网络的PLC技术在电镀生产线上的应用[D].硕士学位论文.江苏:河海大学,2006.5.
[20]聂春泉.自动电镀生产线控制系统[J].工业控制技术,2005,4:2-4.
[21]喻思文.AutoCAD Electrical 2006设计实战[M].长沙:喻思文,2005:20-50.
[22]喻思文. AutoCAD Electrical在华泰重工的使用[J].电气应用,2006,25(4).
[23]闫昆.低压成套开关设备的可靠性研究.硕士学位论文[D].天津:河北工业大学,2006.12.
[24] Chen Jibin. Spray pump control system design and analysis of reliability[J].Building automation.2009.3:18-21.
[25]高有华.多功能继电器、接触器可靠性试验系统[J].沈阳工业大学学报,2001,23(1):1-5.
[26]沙斐,谭海峰.电子产品的电磁兼容控制和设计[J].电子质量北方交通大学电磁抗干扰中心
[27]姚竹亭,吴立新,潘宏侠,刘燕军.某车辆控制系统电磁兼容设计[J].中北大学火炮发射与控制学报,2008,(1):3-4.
[28]王震.控制系统控制柜电磁兼容分析与仿真研究.硕士学位论文[D].哈尔滨:哈尔滨工程大学,2009.1.
[29]赵明.电磁兼容和配线工艺的研究[D].硕士学位论文.北京:北京交通大学,2006.12.
[30] Chen Yongchun. Summary and electromagnetic compatibility EMC in switching power supply technology[J].Electronic products,2008,4:49-51.
[31] Qu Jianchang. Electromagnetic compatibility design of electronic equipment[M]. Beijing: Electronic industry press,2003.
[32]苏惠峰,高莉,段新,负保记.微机继电保护装置的电磁兼容设计[J].电力系统保护与控制, 2009,37(17).2009,12: 97-101.
[33]崔刚,孟庆波,刘文召.电磁兼容EMC控制技术浅析[J].郑州铁路职业技术学院学报. 2008,12 :3-5.
[34]胡思振.阳极电镀自动化生产线的抗干扰措施[J].电工技术, 2009,(3): 38-39.
[35]袁礼东,潘爱强,高玉新. PLC控制系统的抗干扰设计[J].昆明冶金高等专科学校学报.2006,(6):3-4.
[36] Wang Xiao. Improve the measures of PLC control system reliability[J]. University science research,2006,(1):51-52.
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